Chapter 4

Analyses

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Analyses
4-1 Introduction The nature of the investigation carried out on the duct is not simple; rather it involves the Structural, Thermal and the Fluid Flow problems. For most part of the investigation, the structural and thermal analysis are dependent to each other, and accompanying fluid flow problem occurs due to the fact that the duct geometry is not symmetric, also the temperature and pressure varies throughout the duct from inlet to exit. The analysis done can be classified into three different categories: 1) The Structural Analysis: The Structural problem arises because of the thermal stresses that are produced in the structure of the duct at elevated temperatures, and the variations in pressure throughout the duct inner surface area. 2) The Thermal Analysis: This includes the investigation of the heat transfer across the duct walls to the outer surroundings, investigation of heat flow, the heat flux in different directions, and the resulting behavior of the duct structure in accordance with the thermal properties of the structure materials. NOTE: Both the structural and thermal problems are inter-related with each other. 3) The Fluid Flow Analysis: The problems that may occur as described above, urge for the investigation of the different Flow Pattern of the fluid flowing through the duct, this becomes more necessary especially when the inlet and exit areas are not same, and also the overall geometry of the vessel is not symmetric. THE GEAR: So as it is clearly visible that the problem of the fluid flow through a nonsymmetric duct at elevated temperatures and pressures requires multidimensional analytical

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tools, so we used markets one of the leading FEA (Finite Element Analysis) based Computer Soft wares: A) ANSYS V 7.0 (Workbench Environment) B) COSMOS FLOW V 5.0 4-1-1 The ANSYS Workbench Environment In general terms, the ANSYS Workbench Environment provides a framework for integrating the various ANSYS computer-aided engineering tools into a single working environment. The Workbench Environment option form the ANSYS launcher combines the ease-of-use inherent to Design Space with the advanced engineering functionality of ANSYS. By using this interface, ANSYS users gain: Excellent CAD import capabilities with bi-directional CAD associativity. In the course of design optimization, changes you make to the geometry can be reflected in the CAD model. Parametric analysis. CAD parameters (model dimensions) and input parameters (loads and material properties) can be varied to discover the optimum design. These parameters can also be passed to Design explorer. Advanced meshing, including: robust capabilities for meshing complex CAD geometry, enhanced ability to handle small features, automatic sizing, assembly meshing, automatic contact generation, patch independent meshing, automatic sweeping, and automatic mapped meshing. A more intuitive and productive user interface.

4-1-2 Cosmos COSMOS is an open-architecture, multiple-document program that takes advantage of the well-known Windows Graphical User Interface (GUI). The open architecture of COSMOS allows integration with third party analysis software, user customization, and the addition of complementary programs. COSMOS based on the Parasolid geometry engine, also supports ACIS and STEP AP203 standards. COSMOS can directly open several CAD system files. With these capabilities, COSMOS can analyze parts and assemblies created in almost any CAD system. Analysis Capabilities COSMOS allows performing the following types of analyses: Linear stress analysis Natural frequencies and mode shape calculations Critical buckling load estimation

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Chapter 4 Linear and nonlinear steady state and transient heat transfer analysis Nonlinear stress analysis Motion simulation (COSMOS/Motion, not supported in this release) Fluid Flow analysis (COSMOS/Flow)

Analyses

Electromagnetic analysis (COSMOS/EMS In this project Cosmos was used to perform the Fluid Flow analysis using the Cosmos/Flow environment. COSMOS/Flow for COSMOS/DesignSTAR is a fluid flow and thermal analysis program that is integrated in COSMOS/DesignSTAR. COSMOS/Flow solves the mathematical equations which represent heat and momentum transfer in a moving fluid. The finite element method is used to discretize the flow domain, thereby transforming the governing partial differential equations into a set of algebraic equations whose solution represents an approximation to the exact (and most often unattainable) analytical solution. The numerical formulation is derived from the simpler solution scheme introduced by Patanker.

4-2 The Thermal and Structural Simulation The Thermal and Structural Analysis was done using ANSYS engineering software program. Each scenario listed below represents one complete engineering simulation. The definition of a simulation includes known factors about a design such as material properties per part, contact behavior between parts (in an assembly), and types and magnitudes of loading conditions. The results of a simulation provide insight into how the parts may perform and how the design might be improved. Multiple scenarios allow comparison of results given different loading conditions, materials or geometric configurations. In order to simulate the analyses following steps are carried out in the same sequence: i. Import the Model Having run the Ansys, the first step is to import the CAD model.

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Figure 4-1 Half model imported in Ansys workbench environment.

ii.

Define Contacts The surfaces in contact should be explicitly defined. Contact conditions are formed where parts meet. One can transfer structural loads and heat flows across the contact boundaries and to connect the various parts. By default when an assembly is imported from a CAD system contact is automatically detected and contact regions

Figure 4-2 The default contacts defined by the Ansys.

are assigned. The contact default settings and automatic detection capabilities are sufficient for most contact problems. However, more advanced contact controls are available that broaden the range of contact analyses you can perform. The default contacts defined by the Ansys were sufficient so no advanced contact controls were applied. iii. Generate the Mesh Once the geometry has been inserted into the workspace, the first step towards the analysis is to generate the mesh of the part/parts. Since the dust is complex one so some mesh controls were required. ANSYS meshing tools include the mesh control options. The mesh control, which was used, is relevance, applied to the individual parts; the numerical value of relevance was set according to the part complexity to get uniform mesh as shown in Figure 4-3. After applying relevance controls the mesh was solved and the final mesh of the duct is shown in Figure 4-4.

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(a)

(b)

(c)

(d)

Figure 4-3 (a) Relevance applied to ceramic insulation of value 100 (b) Relevance applied to rockwool insulation of value 100 (c) Relevance applied to outer casing of value -100 (d) Relevance applied to inner sheets of value -100

Relevance controls the Fineness of the mesh and defines the acceptable accuracy for each part. As such, it weights the relative importance of all the parts in an assembly. The finer the mesh, the more accurate are the results. A coarse mesh is less accurate.

Figure 4-4 The meshed duct

iv.

Applying the Boundary Conditions (Choose the Environments)

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The ANSYS Workbench Environment allows the user to apply different types of loading conditions simultaneously, and these may be the thermal, structural, force, acceleration, rotational velocity, pressure, moment, or gravitational loads. As far as the ducts structural analysis is concerned the Standard Earth Gravity, the Given Temperature, the Fixed Support, the Frictionless Support, the Convection, and the Pressure Loads are enough to simulate the duct in the real-time manner.

Figure 4-4 The boundary conditions being applied.

The environments can be verified quickly by looking at the icons in front of each environment item in the tree outline. A green check indicates that the requirements are met. A question mark indicates that the requirements are not met. v. Defining Outputs Before running the solution we have to define the desired outputs so that we can interpret the behavior of the duct under given environment (boundary conditions). The outputs that were specified are the plots of Temperature, Equivalent Stress, Equivalent Strain, Total Deformation, Total Heat Flux, Thermal Strain, Maximum Principal Stress, and the Maximum Principal Strain. vi. Engineering Data The material properties were defined in the engineering data folder for each part of the duct. The materials defined for different parts of the duct were PS1010, Rockwool Insulation, and Ceramic Insulation, which are defined, in the Appendix-A. vii. Solution Having defined all the above parameters the solution was run and the outputs were obtained which are discussed in the chapter 5.

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4-3 Fluid Flow Simulation The Fluid flow Analysis was done using COSMOS/Flow engineering software program. Each scenario listed below represents one complete engineering simulation. The half of the fluid volume entrapped in the duct was modeled in Solid Edge because cosmos flow requires the actual fluid volume to perform the fluid flow study rather than only solid parts. Only half of the fluid volume was modeled because of symmetry to reduce analysis time. i. Importing the Model The fluid volume was imported in the cosmos flow similarly as the duct was imported in Ansys as shown in figure 4-7.

Figure 4-7 The Half Fluid Volume.

ii. Defining the Fluid Flow Study After importing the Fluid volume the next step is defining the type of study. The analysis type was selected to be the Fluid flow and the mesh type was selected as solid. In the properties of the study the flow state was set to steady state, flow parameters were internal and turbulent, in compressibility field incompressible was set and in heat transfer field adiabatic was selected. In the component properties the imported part was defined to be fluid while no extended attribute was assigned. The remaining properties of the fluid were defined after launching Cosmos/Flow solver. iii. Applying the Boundary Conditions Different boundary conditions were applied to express the actual situation faced by the fluid volume such as pressure, velocity of flow, temperature.

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First boundary condition applied was slip wall at the section plane as shown in the Figure 4-8 (a). This type of velocity boundary condition allows the fluid to follow the wall. The only condition is to prevent fluid from crossing the boundary. Slip wall condition can also be applied to specify faces of symmetry. This boundary condition can be used with a near-zero viscosity to simulate Euler or inviscid flow. Next boundary condition was velocity of flow at the inlet cross section the value was given as 70 m3/s as shown in Figure 4-8 (b). Next static pressure was defined at the outlet cross section and its value is 950 N/m2 gauge as shown in Figure 4-8 (c). The temperature at the inlet was defined 1400 K as shown in Figure 4-8 (d)

(a)

(b)

(c)

(d)

Figure 4-8 (a) Slip wall condition (b) Inlet Velocity of Flow (c) Static Pressure at Exit (d) Temperature at Inlet

iv. Meshing the Fluid Volume For meshing the fluid volume the mesh quality was set to high and the mesh control was set to automatic transition and smooth surfaces. While creating the mesh the mesh element size was set to the smallest possible value to get the very fine mesh so that the results are more accurate. When mesh quality is set to high the element shape is ten-node tetrahedron. In mesh control selecting automatic transition allows the program to automatically apply mesh controls to small features, details, holes, and fillets, and smooth surface was checked to allow the program to slightly relocate the boundary nodes to improve the initial mesh. The mesh of the fluid volume is shown in the Figure 4-9.

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Figure 4-9 The mesh of the Fluid Volume.

v. Running Analysis After applying all the boundary conditions and generating the mesh Cosmos/Flow solver was launched. In the FI Prop, the properties of the fluid were entered as given in the Appendix-B. The convergence control was applied to pressure (0.05) and velocity (0.1) and the temperature and velocity were initialized. The outputs required were selected from the output popup. The analysis was run for 200 iterations and the results are discussed in chapter 5.

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